US11186014B2 - Process for shaping and process for impregnating a fibrous preform - Google Patents

Process for shaping and process for impregnating a fibrous preform Download PDF

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Publication number
US11186014B2
US11186014B2 US16/642,609 US201816642609A US11186014B2 US 11186014 B2 US11186014 B2 US 11186014B2 US 201816642609 A US201816642609 A US 201816642609A US 11186014 B2 US11186014 B2 US 11186014B2
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fibrous texture
mandrel
fibrous
impregnation
impregnation mandrel
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US20200206978A1 (en
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Pauline Nathalie Six
Nicolas Cambyse Ashtari
Hubert Jean Marie FABRE
Jérémy HELLOT
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Safran Aircraft Engines SAS
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Safran Aircraft Engines SAS
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Assigned to SAFRAN AIRCRAFT ENGINES reassignment SAFRAN AIRCRAFT ENGINES ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ASHTARI, NICOLAS CAMBYSE, FABRE, HUBERT JEAN MARIE, HELLOT, JÉRÉMY, SIX, PAULINE NATHALIE
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/08—Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/748—Machines or parts thereof not otherwise provided for
    • B29L2031/7504—Turbines
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D03D25/005—Three-dimensional woven fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/24—Casings; Casing parts, e.g. diaphragms, casing fastenings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/32—Application in turbines in gas turbines
    • F05D2220/323—Application in turbines in gas turbines for aircraft propulsion, e.g. jet engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced

Definitions

  • the invention relates to the field of gas turbine casings, and more particularly containment casings for gas turbine fans for aeronautical engines.
  • a fan casing fulfils several functions. It defines the air intake duct in the engine, supports an abradable material facing the tips of the vanes of the fan, supports where applicable a structure for absorbing soundwaves for acoustic processing at the engine intake and incorporates or supports a containment shield.
  • the latter constitutes a trap retaining debris, such as ingested objects or fragments of damaged vanes, projected by centrifugation, in order to avoid them crossing the casing and reaching other parts of the aircraft.
  • a fan containment casing made of composite material has already been proposed.
  • the fibrous texture is produced by three-dimensional weaving with varying thickness and is wound in several superimposed layers on a mandrel with a profile corresponding to that of the casing to be manufactured.
  • the fibrous preform thus obtained is retained on the mandrel and an impregnation by resin is performed before polymerization.
  • the winding on a mandrel of a fibrous texture of varying thickness described in this document makes it possible to directly dispose of a tubular preform having the desired profile with a variable thickness.
  • a tackifier for this purpose, it is known to use a tackifier to bond approximately one quarter of the first turn of the fibrous texture during its winding on the mandrel, thus making it possible to make it adhere to the tool.
  • a solution does however require the preparation of the product, leading to an increase in the manufacturing time of the casing.
  • the tackifier is furthermore a chemical agent that can potentially have an adverse effect on the safety and health of the operators.
  • the fibrous texture may, during the winding of its first turn, slip in relation to the mandrel. Such a slipping risk is impossible to detect or measure once the other layers of the fibrous texture are wound on the mandrel.
  • attachment clamps can be put in place to retain the fibrous texture on the mandrel during the winding of the first turn of the fibrous texture.
  • the covering of the fibrous texture by itself then supplies a compressive force sufficient for it to dispense with the clamps and ensure the proper adhesion of the fibrous texture on the mold using the tackifier. The time of shaping of the casing preform from the winding of the fibrous texture is thus extended even further thereby.
  • the aim of this invention is to remedy the aforementioned drawbacks. More precisely, this invention has notably the aim of proposing a solution making it possible to dispense with the use of a tackifier during the winding of the fibrous texture around the mandrel, reduce the manufacturing time of the casing obtained from this fibrous texture and improve the safety of the operators.
  • the invention proposes a process for shaping a fibrous preform implementing an installation comprising a storage mandrel intended to store a fibrous texture in the form of a wound strip, an impregnation mandrel comprising an external surface and an internal surface opposite the external surface, a device for conveying the fibrous texture between the storage mandrel and the impregnation mandrel, inserted into at least one aperture extending between the external and internal surfaces of the impregnation mandrel, and at least one removable retaining device, the process comprising:
  • attachment tabs at the proximal part of the fibrous texture allows for the attachment of the fibrous texture on the impregnation mandrel.
  • This attachment is performed via the insertion of the tabs into respective apertures formed in the impregnation mandrel and by the use of removable devices for holding the tabs in place.
  • this makes it possible to obviate any risk of slipping of the fibrous texture during its winding around the impregnation mandrel.
  • a solution makes it possible to dispense with any use of tackifier.
  • the preparation time of the installation with a view to the winding of the fibrous texture is therefore reduced, as well as the time for shaping of the preform.
  • the absence of use of tackifier furthermore makes it possible to preserve the health of the operators.
  • the proximal part longitudinally comprises a gradual increase in thickness between each attachment tab and the rest of the fibrous texture.
  • the width of each attachment tab extends in a part of constant thickness of the fibrous texture.
  • each attachment tab is formed by two-dimensional weaving.
  • each removable device comprises an attachment screw or a clamping device configured to retain from the inside of the impregnation mandrel an attachment tab against a surface of the impregnation mandrel.
  • each removable retaining device is configured to retain an attachment tab against a surface extending between the internal surface and the external surface, or against the internal surface of the impregnation mandrel.
  • the fibrous texture further comprises a plurality of attachment tabs respectively inserted into a plurality of apertures and a plurality of removable devices for retaining the tabs.
  • the latter further comprises the cutting-out of at least one woven layer extracted from the fibrous texture and distinct from each attachment tab, before the insertion of each tab into the corresponding aperture of the impregnation mandrel.
  • the invention also proposes a process for impregnation of a fibrous preform for the production of a gas turbine casing made of composite material, implementing the steps of the process of shaping of a fibrous preform summarized above, the impregnation process further comprising the steps of:
  • FIG. 1 is a schematic view of an installation for the shaping of a fibrous texture in accordance with an embodiment of the invention
  • FIG. 2 is a schematic perspective view of a loom showing the three-dimensional weaving of a fibrous texture
  • FIG. 3 is a schematic perspective view showing the winding of a fibrous texture on an impregnation mandrel constituting the installation in FIG. 1 in accordance with an embodiment of the invention
  • FIG. 4 is a schematic perspective view of a fibrous texture in accordance with an embodiment of the invention.
  • FIG. 5 is a schematic view showing an exemplary embodiment of a gradual reduction in thickness in the fibrous texture of FIG. 4 making it possible to obtain wedge-shaped edge;
  • FIG. 6 is a partial radial section view of the impregnation mandrel of FIG. 1 , illustrating an example of a removable device ensuring the retaining of the fibrous texture against the impregnation mandrel in accordance with an embodiment of the invention
  • FIG. 7 is a partial radial section view of the impregnation mandrel of FIG. 1 , illustrating another example of a removable device ensuring the retaining of the fibrous texture against the impregnation mandrel in accordance with an embodiment of the invention
  • FIG. 8 is a partial radial section view of the impregnation mandrel of FIG. 1 , illustrating another example of a removable device ensuring the retaining of the fibrous texture against the impregnation mandrel in accordance with an embodiment of the invention
  • FIG. 9 is a partial radial section view of the impregnation mandrel of FIG. 1 , illustrating another example of a removable device ensuring the retaining of the fibrous texture against the impregnation mandrel in accordance with an embodiment of the invention
  • FIG. 10 is a partial radial section view of the impregnation mandrel of FIG. 1 , showing a preform for shaping on the basis of the windings of the fibrous texture around the impregnation mandrel in accordance with an embodiment of the invention
  • FIG. 11 is an axial section half view of a casing preform obtained by winding the fibrous texture on the impregnation mandrel in accordance with an embodiment of the invention
  • FIG. 12 is a section view showing the positioning of the injection sectors on the preform of the casing of FIG. 11 ;
  • FIG. 13 is a perspective view of an aeronautical engine in accordance with an embodiment of the invention.
  • the invention applies in general to the production of cylindrical fibrous preforms having a varying profile in radial section and which are able to constitute fibrous reinforcements, these preforms being intended to be used for the manufacturing of parts made of composite material of cylindrical shapes also having a varying profile and/or a variable thickness particularly in radial section.
  • the radial section corresponds to a plane defined by the axial direction and the radial direction of the mandrel on which the preform is shaped.
  • the axial direction D A and the radial direction D R are in particular indicated in FIG. 1 .
  • the parts are obtained by winding of a fibrous texture on an impregnation mandrel, injection of a fluid composition, such as a resin, into the fibrous preform thus constituted, then heat treatment of said composition in order to obtain the matrix.
  • FIG. 1 represents an installation 10 for the shaping of a fibrous preform with varying shape in accordance with an embodiment of the invention.
  • the installation 10 comprises a storage mandrel 300 intended to store a fibrous texture 100 in the shape of a wound strip.
  • a conveying device 200 is placed downstream of the storage mandrel 300 in the direction of travel of the fibrous texture 100 .
  • An impregnation mandrel 600 also called an injection mold, is arranged downstream of the conveying device 200 .
  • the fibrous texture 100 on the storage mandrel 300 is unwound from the latter to be shaped by winding on the impregnation mandrel 600 , the winding being done under a controlled tension at the storage mandrel 300 .
  • the conveying device 200 is formed of two follower rollers 400 and 500 .
  • any other device capable of conveying the fibrous texture 100 between the storage mandrel 300 and the impregnation mandrel 600 can be envisioned.
  • the device 200 can for example have a greater or lesser number of follower rollers.
  • the fibrous texture 100 is produced in a known manner by weaving by means of a weaving loom of jacquard type 700 on which has been disposed a bundle of warp threads 20 or strands in a plurality of layers, the warp threads being linked by weft threads or strands 30 .
  • the fibrous texture 100 is produced by three-dimensional weaving or by multilayer weaving.
  • three-dimensional weaving or “3D” weaving are understood to mean a method of weaving by which at least some of the weft threads link warp threads 20 on several layers of warp threads or conversely.
  • One example of three-dimensional weaving is so-called “interlock” frame weaving.
  • interlock weaving is understood to mean a weaving frame wherein each layer of weft threads 30 links several layers of warp threads 20 with all the threads of one and the same weft column having the same movement in the plane of the frame.
  • multilayer weaving denotes 3D weaving with several layers of warp threads 20 , for which the base frame of each layer is equivalent to a conventional 2D fabric frame, such as a frame of canvas, satin or serge type, but with certain points of the frame that link the layers of warp together or conversely.
  • the production of the fibrous texture 100 by 3D or multilayer weaving makes it possible to obtain a connection between the layers, and thus to have correct mechanical withstand of the fibrous texture 100 and of the composite material part obtained.
  • the fibrous texture 100 can in particular be woven from threads of carbon fiber, ceramics such as silicon carbide, glass, or else aramid.
  • a shaping weaving also called “contour weaving”, which consists in taking up a different length of warp threads 20 as a function of their position over the width of the fibrous texture 100 woven in the shape of a strip.
  • one or more take-up rollers are used at the extraction of the loom 700 which have over their axial length, defined in a direction D A , a variable radius defining an external surface with a raised profile making it possible to take up different lengths of warp threads 20 as a function of their position over the width of the fibrous texture 100 , a greater length of warp thread being taken up by the party or parties of a take-up roller having a greater radius than the rest of the roller.
  • the differential take-ups produced by the take-up rollers collide with one another when the weaving cell of the loom 700 by pulling the right length of warp thread 20 before the insertion of the next column of weft threads 30 .
  • the texture thus woven is wound on the storage mandrel 300 , also called a “take-up” mandrel, located downstream of the take-up rollers.
  • the fibrous texture 100 is thus stored with a view to its subsequent shaping on the impregnation mandrel 600 .
  • the fibrous preform is shaped by winding on the impregnation mandrel 600 of the fibrous texture 100 .
  • the fibrous texture 100 forms a strip having along the axial direction D A a varying profile, that is to say a variation in shape and/or thickness in cross-section.
  • the impregnation mandrel 600 has in radial section a profile corresponding to that of the part to be produced which corresponds in the example described here to a fan casing of an aeronautical engine.
  • the impregnation mandrel 600 has an external surface 601 , the raised profile of which corresponds to the internal surface of the casing to be produced, and an internal surface 602 opposite the external surface 601 .
  • the fibrous texture 100 follows the profile thereof.
  • the impregnation mandrel 600 also contains two flanges 620 and 630 to form parts of fibrous preform corresponding to the flanges of the casing to be manufactured.
  • the impregnation mandrel 600 can be rotationally driven in the direction of rotation S 600 , for example by an electric motor (not shown), whereas the fibrous texture 100 is tensioned between the storage mandrel 300 and the impregnation mandrel 600 .
  • the first and second follower rollers 400 and 500 forming the conveying device 200 can be driven by the fibrous texture 100 respectively following directions of rotation S 400 and S 500 indicated on FIG. 1 . They have over their axial width, defined along the direction D A , a variable radius in such a way as to respectively define external surfaces 401 , 501 having a raised profile corresponding to the intended profile for the fibrous preform to be produced.
  • the storage mandrel 300 can be mainly rotationally driven in the direction of rotation S 300 and also has over its axial width a variable radius in such a way as to define an external surface 301 having a raised profile corresponding to the profile intended for the fibrous preform in order to limit the distortion of the fibrous texture 100 during its storage.
  • the storage mandrel 300 provides the tensioning of the fibrous texture 100 during its winding, its rotation can be momentarily stopped or reversed with respect to the direction of rotation S 300 in order to maintain the tension on the texture during its winding on the impregnation mandrel 600 .
  • the fibrous texture 100 can present a slipping risk during its winding around the impregnation mandrel 600 . To obviate this risk, the fibrous texture 100 can be produced as illustrated in FIG. 4 .
  • the fibrous texture 100 has a strip shape which extends lengthwise in a longitudinal direction D X corresponding to the direction of travel of the threads or strands of warp 20 and widthwise or transversally in the lateral direction D A between a first and a second lateral edge 101 and 102 , the lateral direction D A corresponding to the direction of the weft 30 threads or strands.
  • the fibrous texture 100 extends longitudinally over a predetermined length L 100 in the direction D X between a proximal part 110 intended to form the start of the winding of a fibrous preform on a shaping tool, here the impregnation mandrel 600 , and a distal part 120 intended to form the end of the winding of the fibrous preform, the proximal and distal parts overlapping one another in the winding.
  • the fibrous texture 100 furthermore has a central area 130 extending over a predetermined width I 130 in the direction D A , the central area 130 being intended to form the barrel or ferrule of the casing.
  • the central area 130 is delimited between two lateral areas 140 and 150 each extending over a predetermined width I 140 , I 150 in the direction D A and over a predetermined length in the direction D X , the lateral areas 140 and 150 being intended at least in part to form the annular flanges of the casing.
  • the proximal part 110 of the fibrous texture 100 includes at least one attachment tab 111 , three in the example illustrated, it being possible to envision a greater or lesser number of tabs.
  • Each attachment tab 111 can have a thickness less than the thickness of the rest of the fibrous texture 100 , and is for example made from a dropped area of the fibrous texture 100 which has been woven as a supplement.
  • the fact that each attachment tab 111 has a thickness less than the rest of the fibrous texture 100 will make it possible to facilitate the subsequent cutting-out of these.
  • the width along the direction D A of each attachment tab 111 can possibly, but not necessarily, extend in a part of constant thickness of the fibrous texture 100 .
  • the proximal part 110 of the fibrous texture 100 can where applicable comprise in the longitudinal direction D X a gradual increase in thickness between each attachment tab 111 and the rest of the fibrous texture 100 .
  • the proximal part 110 of the fibrous texture 100 can comprise a wedge shape 112 , also called “scarf”, which makes it possible to gradually reduce the thickness of the fibrous texture 100 until a minimum thickness is obtained corresponding to the thickness of each attachment tab 111 .
  • FIG. 5 illustrates an exemplary embodiment of a wedge shape 112 for the fibrous texture 100 .
  • the wedge shape 112 is obtained by producing gradual layer extractions in the fibrous texture 100 and by cutting out each of the layers extracted from the fibrous texture. More precisely, on FIG. 5 the fibrous texture 100 includes 4 layers of warp threads C h1 to C h4 linking together 4 layers of weft thread C t1 to C t4 .
  • the weaving of the fibrous texture 100 is modified at the moment of extraction of the layers in order to permit the extraction of a layer of warp threads with the corresponding layer of weft threads.
  • the weaving of the warp threads belonging to the layer of warp threads C h1 changes from a three-dimensional woven structure to a two-dimensional woven structure with the layer of weft threads C t1 at the level of the extraction point S 1 from which the layer of warp threads C h1 and the layer of weft threads C t1 are extracted from the fibrous texture, these layers being cut out at the level of the extraction point S 1 .
  • the same modification of the woven structure is produced between the layers C h2 and C t2 , C h3 and C t3 , and C h4 and C t4 respectively at the level of the extraction points S 2 , S 3 and S 4 from which the layers C h2 and C t2 , C h3 and C t3 , and C h4 and C t4 are extracted from the fibrous texture 100 .
  • the extraction points S 1 to S 4 being offset with respect to one another in the direction D X , a gradual reduction in thickness is thus produced, making it possible to obtain a longitudinal edge of wedge shape 112 .
  • This wedge shape 112 makes it possible to avoid an excessively sudden transition during the stacking of the first turns of the fibrous texture 100 on the proximal part 110 .
  • Each attachment tab 111 is then formed by two-dimensional weaving of the layers C h4 and C t4 .
  • the use of a two-dimensional woven structure for each attachment tab 111 makes it possible to facilitate the subsequent cutting-out of these.
  • the production of a three-dimensional woven structure for each attachment tab 111 does however remain possible.
  • the wedge 112 can be obtained by the cutting-out of at least one woven layer extracted from the fibrous texture 100 , this layer being distinct from the attachment tab 111 .
  • Each attachment tab 111 can then be woven in the extension of the minimum thickness of the wedge 112 in such a way as to have a minimized number of layers, with a view to facilitating its cutting-out.
  • the impregnation mandrel 600 comprises one or more apertures 610 .
  • Each aperture 610 extends between the external surface 601 and the internal surface 602 of the impregnation mandrel 600 and is produced in such a way as to allow the insertion of a corresponding attachment tab 111 through it.
  • the installation 10 further comprises one or more removable devices 80 - 1 , 80 - 2 for retaining the attachment tabs 111 .
  • Each removable device 80 - 1 , 80 - 2 is configured to retain from the inside of the impregnation mandrel 600 an attachment tab 111 , inserted into a corresponding aperture 610 , against a surface of the impregnation mandrel 600 .
  • the surface of the impregnation mandrel 600 against which the attachment tab 111 is maintained can be the internal surface 602 of the mandrel. This first example has the advantage of proposing the retainment of the attachment tab 111 independent of the width of the aperture 610 .
  • FIGS. 1 the surface of the impregnation mandrel 600 against which the attachment tab 111 is maintained
  • the surface of the impregnation mandrel 600 against which the attachment tab 111 is retained can be a surface 603 extending between the external surface 601 and the internal surface 602 , i.e. a surface 603 partly delimiting the aperture 610 .
  • This second example has the advantage of being able to reduce the length of each attachment tab 111 .
  • care is taken to adapt the width of the aperture 610 in order to permit the placement of the removable device 80 - 1 , 80 - 2 of retainment via the inside of the impregnation mandrel 600 .
  • the removable device 80 - 1 is of screw/nut type and retains using an attachment screw 81 the tab 111 respectively against the internal surface 602 or the surface 603 of the impregnation mandrel 600 .
  • an attachment plate 82 can where applicable be disposed between an internal face (i.e. facing the mandrel) of the attachment tab 111 and the attachment screw 81 .
  • the plate 82 is capable of being tightened against the tab 111 by means of the attachment screw 81 , in such a way as to exert a clamping force on the attachment tab 111 , this force being exerted between the internal surface 602 of the impregnation mandrel 600 and the plate 82 .
  • the removable device 80 - 2 comprises a clamping device 83 , such as clamps bearing on at least one of the flanges 620 , 630 of the impregnation mandrel 600 and then retaining, by clamping, the tab 111 respectively against the internal surface 602 or the surface 603 of the impregnation mandrel 600 .
  • the obtainment of a fibrous preform 800 from the fibrous texture 100 is performed as follows.
  • the fibrous texture 100 is unwound from the storage mandrel 300 and conveyed toward the impregnation mandrel 600 using the conveying device 200 .
  • Each attachment tab 111 of the fibrous texture 100 is then inserted into a corresponding aperture 610 of the impregnation mandrel 600 .
  • each attachment tab 111 is attached against a surface of the impregnation mandrel 600 , for example the internal surface 602 or the surface 603 , using a removable device 80 - 1 , 80 - 2 .
  • the fibrous texture 100 is then unwound under tension around the impregnation mandrel 600 , until the obtainment of a fibrous preform 800 , illustrated by way of example in FIG. 10 .
  • each removable device 80 - 1 , 80 - 2 is then withdrawn from the inside of the mandrel.
  • the attachment screws 81 , attachment plates 82 and/or clamping devices 83 are withdrawn so as to leave free each attachment tab 111 inserted into each aperture 610 .
  • Each attachment tab 111 then projects toward the inside of the impregnation mandrel 600 .
  • Each attachment tab 111 then undergoes a cutting-out operation from the inside of the impregnation mandrel 600 , for example using a Stanley knife blade.
  • attachment tabs 111 have a lower thickness vis-à-vis the rest of the fibrous texture 100 .
  • a blank 84 is inserted into each aperture 610 of the impregnation mandrel, in such a way as to blank them off.
  • FIG. 11 shows a section view of the fibrous preform 800 obtained after winding of the fibrous texture 100 in several layers on the impregnation mandrel 600 , the view showing the preform in the area of overlap between the distal part 120 and the proximal part 110 of the fibrous texture 100 .
  • the number of layers or twists is a function of the desired thickness and the thickness of the fibrous texture 100 . It is preferably at least equal to 2.
  • the preform 800 comprises four layers of fibrous texture 100 .
  • a fibrous preform 800 is obtained with a central part 810 and end parts 820 , 830 of lesser thickness corresponding to the flanges of the casing to be produced.
  • the densification of the fibrous preform 800 is produced by a matrix.
  • the densification of the fibrous preform 800 consists in filling the porosity of the preform, in all or part of the volume thereof, with the constituent material of the matrix.
  • the matrix can be obtained in a manner known per se following the process by liquid means.
  • the process by liquid means consists in impregnating the preform with a liquid composition containing an organic precursor of the matrix material.
  • the organic precursor usually takes the form of a polymer, such as a resin, where applicable diluted in a solvent.
  • the fibrous preform 800 is placed in a mold, here on the impregnation mandrel 600 , which can be closed in an airtight manner with a housing having the shape of the molded final part.
  • the fibrous preform 800 is here placed between a plurality of sectors 650 forming a counter-mold and the impregnation mandrel 600 forming a support, these elements respectively having the external shape and the internal shape of the casing to be produced. Then, the matrix liquid precursor is injected, for example a resin, into the entire housing to impregnate the whole fibrous part of the preform.
  • the matrix liquid precursor is injected, for example a resin, into the entire housing to impregnate the whole fibrous part of the preform.
  • the conversion of the precursor into an organic matrix is performed by heat treatment, generally by heating of the mold, after elimination of any solvent and cross-linking of the polymer, the preform being always retained in the mold having a shape corresponding to that of the part to be produced.
  • the organic matrix can be notably obtained from epoxy resins, such as, for example the high-performance epoxy resin on sale, or liquid precursors of carbon or ceramic matrices.
  • the heat treatment consists in pyrolyzing the organic precursor to convert the organic matrix into a carbon or ceramic matrix according to the precursor used and the conditions of pyrolysis.
  • carbon liquid precursors can be resins with a relatively high degree of coke, such as phenolic resins
  • ceramic liquid precursors notably of SiC
  • PCS polycarbosilane
  • PTCS polytitanocarbosilane
  • PSZ polysilazane
  • the densification of the fibrous preform can be produced by the well-known process of transfer molding, so-called RTM (Resin Transfer Molding).
  • RTM Resin Transfer Molding
  • the fibrous preform is placed in a mold having the shape of the casing to be produced.
  • a thermosetting resin is injected into the internal space delimited between the part made of rigid material and the mold and which comprises the fibrous preform.
  • a pressure gradient is generally established in this internal space between the place where the resin is injected and the orifices of evacuation of the resin in order to control and optimize the impregnation of the preform with the resin.
  • the resin may be, for example, an epoxy resin.
  • the resins suitable for RTM processes are well-known. They preferably have a low viscosity to facilitate their injection into the fibers. The choice of the temperature class and/or the chemical nature of the resin is determined according to the thermomechanical stresses to which the part must be submitted.
  • the casing 900 represented in FIG. 13 is a casing of a fan of a gas turbine aeronautical engine 1000 .
  • Such an engine as shown very schematically by FIG. 13 comprises, from upstream to downstream in the direction of flow of the gas stream, a fan 1100 disposed at the engine intake, a compressor 1200 , a combustion chamber 1300 , a high-pressure turbine 1400 and a low-pressure turbine 1500 .
  • the engine is housed inside a casing comprising several parts corresponding to different elements of the engine.
  • the fan 1000 is surrounded by the casing 900 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Woven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Reinforced Plastic Materials (AREA)
US16/642,609 2017-08-30 2018-08-29 Process for shaping and process for impregnating a fibrous preform Active 2038-11-29 US11186014B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR1757984A FR3070304B1 (fr) 2017-08-30 2017-08-30 Installation, procede de mise en forme et procede d'impregnation d'une preforme fibreuse
FR1757984 2017-08-30
PCT/FR2018/052119 WO2019043335A1 (fr) 2017-08-30 2018-08-29 Procede de mise en forme et procede d'impregnation d'une preforme fibreuse

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FR (1) FR3070304B1 (fr)
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FR3142202A1 (fr) * 2022-11-21 2024-05-24 Safran Ceramics Ebauche fibreuse avec une variation d’épaisseur présentant des croisements de fils
US12017419B1 (en) * 2023-01-04 2024-06-25 Beihang University Three-dimensional orthogonal woven composite outlet guide vane and manufacturing method thereof

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US11040512B2 (en) * 2017-11-08 2021-06-22 Northrop Grumman Systems Corporation Composite structures, forming apparatuses and related systems and methods
GB202210346D0 (en) * 2022-07-14 2022-08-31 Rolls Royce Plc Woven structure, method and apparatus for a flanged composite component

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Publication number Priority date Publication date Assignee Title
US20230286227A1 (en) * 2020-09-16 2023-09-14 Safran Aircraft Engines Mold for manufacturing a turbomachine fan casing made of a composite material with differential expansion
US11993032B2 (en) * 2020-09-16 2024-05-28 Safran Aircraft Engines Mold for manufacturing a turbomachine fan casing made of a composite material with differential expansion
FR3142202A1 (fr) * 2022-11-21 2024-05-24 Safran Ceramics Ebauche fibreuse avec une variation d’épaisseur présentant des croisements de fils
WO2024110703A1 (fr) * 2022-11-21 2024-05-30 Safran Ceramics Ebauche fibreuse avec une variation d'epaisseur presentant des croisements de fils
US12017419B1 (en) * 2023-01-04 2024-06-25 Beihang University Three-dimensional orthogonal woven composite outlet guide vane and manufacturing method thereof

Also Published As

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US20200206978A1 (en) 2020-07-02
FR3070304B1 (fr) 2020-12-11
WO2019043335A1 (fr) 2019-03-07
FR3070304A1 (fr) 2019-03-01

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